Lightweight structural finish

ABSTRACT

A lightweight finish composition, method of production and a method of application are provided. The lightweight finish composition comprises a resin dispersion or emulsion, alkali metal phosphate, alkylolammonium salt of a polyfunctional polymer, and lightweight aggregate such as silica spheres. The lightweight aggregate has a density and weight that is less than those of sand. The combination of alkali metal phosphate and alkylolammonium salt of a polyfunctional polymer stabilizes the lightweight finish composition and may prevent the lightweight aggregate from continuously absorbing water over time, after production of the lightweight finish composition.

This application is a continuation-in-part of U.S. Ser. No. 12/422,768,filed on Apr. 13, 2009, which is a divisional application of U.S. Ser.No. 11/055,351 filed Feb. 10, 2005, now U.S. Pat. No. 7,538,152, both ofwhich are hereby incorporated by reference.

Exterior insulation and finish systems (EIFS) are multi-layered exteriorwall systems that are used on both commercial buildings and homes. EIFStypically comprise the following components: insulation board made ofpolystyrene or polyisocyanurate foam, which is secured to the exteriorwall surface with a specially formulated adhesive and/or mechanicalattachment; a durable water-resistant base coat, which is applied on topof the insulation and reinforced with fiberglass mesh for addedstrength; and a usually textured and durable finish coat typicallyproduced using an acrylic co-polymer technology.

The finish coat composition usually contains, in addition to theco-polymer, an aggregate that is used for the appearance and durabilityof the finish coat composition. The coatings used as the outermost layerin EIFS are typically supplied in 5-gallon pails that weigh about 70pounds each. The heavy weight of the pails slows down the productivityof the workers during application of the finish.

To reduce the weight of these finish compositions the aggregatecomponent has been partially replaced with a lighter material to form alightweight finish. Lightweight finishes utilize naturally occurringaggregates such as perlite, hyperlite, vermiculite, expanded clay andpumice stone. Due to their high porosity, coating these minerals withsilicone is one method employed to prevent the absorption of water andthickening of the textured finish in the prior art. If the light weightnaturally occurring aggregate is not completely coated or the coating issomehow compromised, shelf life problems can occur due to the excessiveviscosity of the packaged finish composition.

Therefore, it is desirable to provide a finish composition which islightweight but does not become excessively viscous after addition ofthe lightweight aggregate. Additionally, it may be desirable to providea lightweight aggregate which is not coated but still allows the finishcoating to maintain a stable viscosity over a period of time.

A lightweight finish composition is provided that comprises a resindispersion or emulsion, a combination of an alkali metal phosphate (AMP)and an alkylolammonium salt of a polyfunctional polymer (ASPP), andlightweight aggregate. The lightweight aggregate is used to replace atleast a portion of the standard aggregate component in finishcompositions and has a density and weight that is less than sand.According to one theory it is believed that the combination of thealkali metal phosphate and alkylolammonium salt of a polyfunctionalpolymer may be used to stabilize the lightweight finish composition bywetting out the generally porous lightweight aggregate. “Wetting” or“wetted out” is a term common in the industry that indicates the airvoid volume of a solid substance or particle has been completely orsubstantially filled with a liquid. This wetting action allows the voidsof the lightweight aggregate to be substantially filled with liquid,thereby preventing the lightweight aggregate from continually absorbingadditional water from the finish composition over time. The preventionof continual water absorption over time by the lightweight aggregateaccording to this theory is provided by the combination of thesurfactants, alkali metal phosphate and alkylolammonium salt of apolyfunctional polymer.

Therefore, without any precoating of the lightweight aggregate, a stablelightweight finish composition is produced such that one week afterproducing the lightweight finish composition the viscosity as measuredin paste units (PU) does not measure more than about 140 paste units anddoes not deviate by more than about 7 paste units in subsequentmeasurements. In certain embodiments, the viscosity of the subjectlightweight finish composition as measured at three weeks aftercombining the resin dispersion or emulsion, a combination of alkalimetal phosphate and an alkylolammonium salt of a polyfunctional polymer,and the lightweight aggregate, does not measure more than about 140paste units. In certain embodiments, the viscosity of the lightweightfinish composition as measured at six weeks after combining the resindispersion or emulsion, a combination of an alkali metal phosphate andan alkylolammonium salt of a polyfunctional polymer, and the lightweightaggregate is less than about 130 paste units (PU).

The lightweight finish composition is “produced” when the resindispersion or emulsion, a combination of an alkali metal phosphate andan alkylolammonium salt of a polyfunctional polymer, and the lightweightaggregate are combined.

The properties of the lightweight aggregate can increase the coveragerate as well as improve the handling and application characteristics ofthe lightweight finish composition. The lightweight finish compositionretains the texture, appearance and durability characteristics ofexisting finishes. The composition can be of various colors and iseasily applied to an exterior and/or interior surface, providing uniformdurable coverage and having the look and feel of the desired texture.

The lightweight finish composition can reduce the weight of a 5-gallonpail of finish coating material from 70 pounds to 45-50 pounds, yetprovides the same surface area coverage rate. In certain embodiments atleast 50% of the volume of the standard aggregate such as silica sand orgravel is replaced with lightweight aggregate.

Lightweight aggregates are aggregate materials that have a density andweight that is less than those of sand (which is a density less thanabout 22 pounds per gallon). They provide strength and in certainembodiments, texture to the finish composition. The lightweightaggregate may be at least one of perlite, vermiculite, fly ash, silicaspheres, microballoons, extendospheres, expanded clay, or pumice stonepowder, or the like. The lightweight aggregate is porous and may be alow absorption aggregate or a high absorption aggregate. A lowabsorption lightweight aggregate typically has a water absorption valueof about 6% by weight or less, whereas a high absorption lightweightaggregate typically has a water absorption value of greater than about6% by weight. In certain embodiments, the silica spheres are at leastone of glass spheres or ceramic spheres, such as those available fromSISCOR, Toronto, Canada. In certain embodiments, the glass spheres maybe hollow silica microspheres and cellular in nature, such as thoseavailable from OMEGA MINERALS, Noderstedt, Germany. In certainembodiments, the lightweight aggregate may be uncoated, meaning that thelightweight aggregate is not treated with a water repellant or a waterresistant coating. In certain embodiments, the lightweight aggregate maybe an uncoated, low absorption silica glass sphere or an uncoated, highabsorption silica glass sphere, or a combination thereof.

Surfactants are additives which reduce surface tension, and may formmicelles to thereby improve wetting, help disperse pigments, inhibitfoam, or emulsify. While not being limited to any theory, it is believedthat the combination of alkali metal phosphate and alkylolammonium saltof a polyfunctional polymer surfactant lowers the surface tension of thewater such that the water is able to fill the voids in the lightweightaggregate, thereby preventing further absorption of water and preventingsubstantial increase in the viscosity of the lightweight finishcomposition. In certain embodiments, the alkali metal phosphate ispotassium tripoly phosphate (KTPP) and the alkylolammonium salt of apolyfunctional polymer is at least one of an alkylolammonium salt of apolyacrylate or an alkylolammonium salt of a polymethacrylate. Anexample of an alkylolammonium salt of a polyfunctional polymer isDisperbyk® 187 produced by BYK Chemie GmbH of Wesel, Germany.

In certain embodiments, the surfactant may comprise from about 0.05% toabout 3% of alkali metal phosphate (AMP) and from about 0.05% to about3% of alkylolammonium salt of a polyfunctional polymer (ASPP), thepercentages of both components being based on the total weight of thelightweight finish composition, provided that the total amount of ASPPand AMP utilized is less than about 4.5 weight percent of thelightweight finish composition. In other embodiments, if the totalamount of ASPP and AMP is greater than about 3 weight percent of thelightweight finish composition, the ratio of ASPP to AMP or the ratio ofAMP to ASPP is greater than about 3:1.

The resin dispersion or emulsion, functions as the binder within thelightweight finish composition. Resin dispersions or emulsions maycomprise acrylic polymers which are aqueous dispersions of polymers,copolymers, or terpolymers of acrylic acid, acrylic acid ester,methacrylic acid, methacrylic acid ester, styrene acrylic acid, styreneacrylic acid ester, acrylonitrile, non-acrylic polymers such aspolyvinyl acetate, styrene butadiene or mixtures thereof. Polymers thatmay be used can have greater or lesser flexibility depending upon thedesired properties of the final finish product. A highly flexible latexwill provide, for example, an elastomeric finish.

In addition to lightweight aggregate, alkali metal phosphate,alkylolammonium salt of a polyfunctional polymer and resin dispersionsor emulsions, the lightweight finish composition may also containcomponents such as solvents, coalescing agents, thickening agents,defoamers, preservatives, flash rust inhibitor, fillers, pigments, orstandard aggregate.

A solvent is a liquid and can include odorless mineral spirits andcoalescents. Solvents aid in the development and formation of a film bythe polymer in the curing process of the coating. They can be used inthe manufacture of a coating to dissolve or disperse the film formingconstituents. After application the solvent evaporates during drying andtherefore does not become part of the dried film. A coalescing agent isa solvent with a high boiling point which, when added to a coating, aidsin film formation via temporary plasticization (softening) of the liquidvehicle Coalescing agents may include diethylene-glycol ethyl ether,diethylene glycol ethyl ether acetate, hexylene glycol, and2-butoxyethanol acetate, and the like. Suppliers of coalescents includeEastman Chemical—Perth Amboy, N.J., Dow Chemical—Midland, Mich. andUnion Carbide—Houston, Tex.

Another solvent is odorless mineral spirits, which is a clear liquidsolvent that is added to reduce stickiness in application. The additionof odorless mineral spirits lowers the surface tension of the coatingwhich allows for a slower cure rate immediately after application to asurface.

A thickening agent, also referred to as a rheology modifier, is anymaterial used to thicken a liquid and/or an additive used to thicken(increase viscosity) or modify the rheology of a coating. The thickeningagent increases the viscosity of the lightweight finish composition toprovide a consistency which allows the application of a single thickfilm or multiple applications to build up a thick film on a verticalsurface. The thickening prevents sagging of the thick film of thelightweight finish composition on a vertical surface prior to set up ordrying.

Thickening agents that may be used include alkali soluble emulsions,hydrophobically modified alkali soluble emulsions, alginates,hydroxyethyl cellulose, hydrophobically modified hydroxyethyl cellulose,hydrophobically modified polyurethanes, and acrylic polymers such asacrylamides, and hydrophobically modified polyacrylamides. In certainembodiments thickening agents may include alkali soluble emulsions,hydrophobically modified alkali soluble emulsions, and hydroxyethylcellulose. Suppliers of thickening agents that can be used are Rohm andHaas—Philadelphia, Pa. and Union Carbide—Houston, Tex.

A defoamer is an additive used to reduce or eliminate foam formed in acoating or a coating constituent. Examples of defoamers are mineral oilbased defoamers, such as silica filled polymethylsiloxane and NOPCO®NXZproduced by Henkel Corporation—Gulph Mills, Pa. Further examples ofcommercially available defoamers include products available fromCrucible Chemical Company—Greenville, S.C.

A preservative may be a biocide which is used to prevent spoilage causedby bacterial growth in a coating that can cause odor or produce enzymesthat can break down defoamers, coalescing agents, dispersants,stabilizers and thickening agents such as cellulosic thickeners used inaqueous paints and coatings. The addition of a biocide will contributeto preventing gas formation and foul odor, along with avoiding adverseeffects on viscosity and stability. Examples of preservatives are aminoalcohols, such as NUOSEPT®91 produced by International SpecialtyProducts—Wayne, N.J., DOWICIL™ 75 and DOWICIL™ QK-20 manufactured by TheDow Chemical Company—Midland, Mich. Other companies providingcommercially available biocides include Troy Chemical—Hackensack, N.J.and CreaNova—Piscataway, N.J. In certain embodiments, the preservativemay be a fungicide or a mildewcide which may be included in thecomposition instead of or in addition to a biocide. The addition of afungicide or mildewcide helps with resistance to fungal growth of thecoating on the wall. Commercially available fungicides and mildewcidescan be obtained from Troy Chemical—Hackensack, N.J.,Creallova—Piscataway, N.J. and Rohm and Haas—Philadelphia, Pa. Otherbiocides and fungicides include halogenated acetylene alcohols, diphenylmercuric dodecenyl succinate, o-phenylphenol and its sodium salt,tri-chlorophenols and their sodium salts.

A flash rust inhibitor is an additive used to inhibit the corrosion thatoccurs during the drying process of a water-based coating. Examples offlash rust inhibitors generally used in the industry are sodium benzoateand sodium nitrite.

Fillers/pigments are finely ground, natural or synthetic, inorganic ororganic, insoluble dispersed particles (such as powder) which, whendispersed in a liquid vehicle to make a coating, may provide, inaddition to color, many of the properties of the coating such asopacity, hardness, durability, etc. Additionally, fillers may be addedto lower the cost of the lightweight finish composition. Fillers, alsoreferred to as extenders, which may be used include clay, mica andwollastonite.

Clay fillers may include fine china clay/aluminum silicate fillers. Forexample, Kaofine™ is a coating clay that is available from the ThieleKaolin Company of Sandersville, Ga. In addition, other commerciallyavailable clay fillers are available from Huber EngineeredMaterials—Atlanta, Ga. In certain embodiments, coarse fillers are usedand may be calcium carbonate or silica flour of a 200-mesh size (oraverage of 75 microns).

In certain embodiments, colored or white pigments including mineralproducts which can be used as fillers and extenders may be used. Amongthe pigments that may be used are the various water insoluble organicand inorganic paint pigments which include, but are not limited to, ironoxides, titanium dioxide, zinc oxide, phthalocyanine blue and green,lead chromate, barium sulfate, zinc sulfide, silica, calcium carbonate,chrome green, iron blues and magnesium silicate (talc). Pigmentdispersing agents, including but not limited to, tetrasodiumpyrophosphate, lecithin, gum Arabic, sodium silicate, various watersoluble soaps, aliphatic and aromatic sulfonates, the aliphaticsulfates, various polyethers and ether alcohol concentrates and thelike, may be added to enhance the dispersion of the pigments.

Standard aggregates are inert solid mineral containing materials, suchas natural sand, manufactured sand, gravel, and the like. Aggregates aresolid granular particles which may impart surface texture to the driedlayer of the exterior finishing composition. Further, the size of theaggregate may be used to determine the minimum applied thickness of theexterior finishing composition, especially for application by trowel.Suitable aggregates include sand and stone chips such as marble chipsand granite chips.

The lightweight finish composition may contain other components such asemulsifiers; dispersants; curing agents; plasticizers; fibers such aspolyethylene fiber, wollastonite, cellulose fiber, and glass fiber; andpH modifiers such as sodium hydroxide, potassium hydroxide,2-methyl-1-propanol, and ammonia.

In certain embodiments the alkali metal phosphate may comprise potassiumtripoly phosphate and the alkylolammonium salt of a polyfunctionalpolymer may comprise at least one of an alkylolammonium salt of apolyacrylate, or an alkylolammonium salt of a polymethacrylate. Thelightweight aggregate may comprise at least one of perlite, vermiculite,fly ash, silica spheres, microballoons, extendospheres, expanded clay,or pumice stone powder. In certain other embodiments the silica spheresare at least one of glass spheres or ceramic spheres. The resindispersion or emulsion, may comprise acrylic polymers which are aqueousdispersions of polymers, copolymers, or terpolymers of acrylic acid,acrylic acid ester, methacrylic acid, methacrylic acid ester, styreneacrylic acid, styrene acrylic acid ester, acrylonitrile, non-acrylicpolymers such as polyvinyl acetate, styrene butadiene or mixturesthereof.

The lightweight finish composition may be used in exterior and interiorapplications such as multilayered exterior wall systems, including EIFS.The lightweight finish composition may be applied onto horizontalsurfaces as well as vertical surfaces.

Various methods may be used to apply the lightweight finish compositionincluding troweling, spraying with air or airless hopper guns, brushing,rolling extruding, and the like.

A “paste unit” (PU) is defined as a viscosity measurement made with aStormer viscometer using a spindle with two thin bars extending from acentral shaft.

To counter the tendency of glass spheres to absorb water andsubstantially thicken compositions, several samples were prepared tostabilize the lightweight finish composition by using a combination ofalkali metal phosphate and alkylolammonium salt of a polyfunctionalpolyacrylate, to wet out the lightweight aggregate.

The samples were prepared using a ribbon blender or Schold mixer. Thelightweight finish composition may be prepared by admixing thecomponents using conventional mixing methods known in the art, includingpaddle type mixers, high speed dispersators, and ribbon blenders. Toprepare the lightweight finish composition, water, alkali metalphosphate, alkylolammonium salt of a polyfunctional polyacrylate andglass spheres were first added to the blender/mixer followed by thecomponents listed below. Samples S1-S10 shown below were prepared usingthe basic finish formulation shown in Table 1:

TABLE 1 Component Wt (lb) Vol (gal) Water 10.2 1.2 Mineral Oil BasedDefoamer 0.15 0.02 Silica Spheres 11.2 3.4 Acrylic Polymer 26 2.94Silica Sand 27 1.22 Wt (lb)—weight in pounds Vol (gal)—volume in gallons

Results of the tests for Samples S1-S10 are set forth in Table 2.

TABLE 2 Weight Weight ASPP Percent AMP Percent Initial ViscosityViscosity Viscosity Viscosity Viscosity (gm/ ASPP (gm/ AMP Viscosity WPG1 Day 1 week 2 weeks 3 weeks 4 weeks Sample gal) (Total) gal) (Total)(PU) lbs. (PU) (PU) (PU) (PU) (PU) S1 0 — 0 — 89 9.6 102 unstable S2 120.28 4 0.09 79 9.5 89 126 134 135 128 S3 16 0.38 4 0.09 82 9.4 89 132141 140 139 S4 24 0.55 8 0.18 76 9.7 81 122 131 128 135 S5 24 0.56 0 —79 9.4 91 139 unstable S6 12 0.27 8 0.18 76 9.7 85 136 137 138 136 S7 160.38 6 0.14 76 9.3 83 117 129 123 126 S8 16 0.37 8 0.19 73 9.5 79 115120 119 119 S9 0 — 8 0.18 88 9.4 96 136 138 unstable S10 24 0.56 4 0.0974 9.4 83 122 125 126 131 PU = paste unit WPG = weight per gallon ASPP =alkylolammonium salt of a polyfunctional polyacrylate AMP = alkali metalphosphate Gm/gal = grams per gallon

Initial viscosity of the sample finish compositions (S1-S10) is low,around 70 to 90 PU. Within a couple of days, the samples containinglightweight aggregate that had been wetted out in the presence of alkalimetal phosphate and alkylolammonium salt of a polyfunctionalpolyacrylate (S2-S4, S6-S8, and S10) had stable viscosities over aperiod of time. This is in comparison to the samples that were notstable over time, which contained neither ASPP or AMP (S1); or, solelyAMP (S5) or solely ASPP(S9). Samples 51, S5, and S9 were listed in Table2 as unstable when no more measurements could be obtained, whichgenerally indicated a viscosity of above 140 PU's.

TABLE 3 Component Wt (lb) Vol (gal) Water 10.2 1.2 Mineral Oil BasedDefoamer 0.15 0.02 Silica Spheres 11.2 3.4 Acrylic Polymer 26 2.94Silica Sand 27 1.22 ASPP 0.6 0.07 AMP 0.3 0.01 Wt (lb)—weight in poundsVol (gal)—volume in gallons ASPP = alkylolammonium salt of apolyfunctional polyacrylate AMP = alkali metal phosphate

All samples tested in Table 4 were prepared as described with respect toSamples S1-S10 and contained the finish formulation shown in Table 3.Application testing of the textured finish compositions described inTable 3 showed good application properties and texture.

TABLE 4 Samples S11 S12 S13 Initial Visc. 71 PU 83 PU 87 PU PH 10.1 10.110.1 WPG 9.5 8.9 9.9 Drying Time RT 4 hrs 6 hrs 4 hrs 40 F. 16 hrs 18.5hrs 16 hrs Wash-off (40 F.) Pass pass Pass Coverage per ft² 0.35 lbs.0.38 lbs. 0.33 lbs. per 45 lbs. 129 ft² 118 ft² 136 ft² per 50 lbs. 143ft² 132 ft² 152 ft² Storage Stability   1 day 79 PU 91 PU 100 PU   1week 120 PU 129 PU 127 PU   2 weeks 119 PU 127 PU 129 PU   3 weeks 117PU 125 PU 125 PU   4 weeks 121 PU 132 PU 126 PU Water Absorption 24 hrs12.2% 14.1% 12.5% 48 hrs 12.5% 14.4% 12.7% Water Pick Up (lb./ft²) 0.5hr. 0.0610 0.0729 0.0647   1 hr. 0.0719 0.0883 0.0741   2 hr. 0.08010.0985 0.0838   3 hr. 0.0834 0.1051 0.0868   4 hr. 0.0873 0.1071 0.0903  5 hr. 0.0893 0.1108 0.0916   6 hr. 0.0895 0.1098 0.0926   7 hr. 0.08790.1083 0.0909   8 hr. 0.0873 0.1049 0.0901  24 hr. 0.0805 0.0911 0.0844 48 hr. 0.0877 0.0938 0.0885 RT = room temperature WPG = weight pergallon PU = paste unit

The samples (S11-S13) maintained a low viscosity over time with littleincrease in PU noted after 1 week of storage. Additionally, the coverageper square foot (ft²) of the samples was improved over finishcompositions containing standard aggregate, which average 0.5 pounds perft² coverage.

Sample finishes S14 to S30 shown below in Table 7 were prepared andtested as described with respect to Samples S1-S10 with varying amountsof potassium alkali metal phosphate and alkylolammonium salt of apolyfunctional polymer. The basic finish formulation utilized for samplefinishes S14-S30 is shown below in Table 5.

TABLE 5 Component Wt (lb) % by Wt Water ~114 to ~175  ~9.5 to ~16.5Liquid Defoamer ~1.25 to ~1.86 ~0.13 to ~0.15 Inorganic Thickener ~10 to~15 ~1.0 to ~1.2 Silica Spheres  ~95 to ~145 ~9.5 to ~12  AcrylicPolymer - Thickener ~6.5 to ~20  ~0.65 to ~1.5  Acrylic Polymer - Binder~225 to ~320 ~22 to ~25 Coalescing Agent ~3.3 to ~7.2 ~0.3 to ~0.6Solvent   ~3 to ~4.4 ~0.3 Calcium Carbonate ~150 to ~240 ~15 to ~20Silica Sand ~215 to ~310 ~22 to ~25 Wt (lb)—weight in pounds % byWt—percent by weight of the finish composition

Sample finishes S31-S46 shown below in Table 7 were prepared asdescribed with respect to Samples S1-S10 with varying amounts ofpotassium alkali metal phosphate and alkylolammonium salt of apolyfunctional polymer. The basic finish formulation utilized for samplefinishes S30-S46 is shown below in Table 6.

TABLE 6 Component Wt (lb) % by Wt. Water ~114 to ~167 ~11.4 to ~16.7Liquid Defoamer ~1.4 ~0.14 Solvent ~11.7 ~1.17 Silica Spheres ~104.5~10.45 Acrylic Polymer - Thickener ~15.0 ~1.5 Acrylic Polymer - Binder~245 ~25.0 Coalescing Agent ~4.5 ~0.45 Solvent ~3.4 ~0.3 CalciumCarbonate ~164 ~16.4 Silica Sand ~237.5 ~23.75 Wt (lb)—weight in pounds% by Wt—percent by weight of the finish composition

The sample finishes of Tables 5 and 6 included potassiumtripolyphosphate as the alkali metal phosphate component and Disperbyk®187 as the alkylolammonium salt of a polyfunctional polymer. Each samplecontained a specific amount of alkali metal phosphate andalkylolammonium salt of a polyfunctional polymer that was measured inweight percent by total weight of the lightweight finish composition.Also, each sample finish was prepared with one of two different types oflightweight glass aggregates which are labeled in Table 5 as “Aggregate1”, “Aggregate 2”, and “Aggregate 3”. “Aggregate 1” and “Aggregate 3”were uncoated, high absorption glass silica spheres while “Aggregate 2”was an uncoated, low absorption glass silica sphere. Uncoated, as usedherein, means that the aggregate was not treated with a water repellantor a water-resistant coating.

Samples S14-S30 include samples having specific amounts of a combinationof ASPP and AMP used with an uncoated, high absorption lightweight glassaggregate, “Aggregate 1”, and corresponding samples containing the sameamounts of ASPP and AMP used with an uncoated, low absorptionlightweight glass aggregate, “Aggregate 2”. Likewise, samples S31-S46include samples having specific amounts of a combination of ASPP and AMPused with an uncoated, low absorption lightweight glass aggregate“Aggregate 2” and corresponding samples containing the same amounts ofASPP and AMP used with an uncoated, high absorption glass aggregate,“Aggregate 3”.

TABLE 7 Vis- Vis- Vis- Vis- Vis- Vis- Vis- Vis- cosity cosity cositycosity cosity cosity cosity cosity ASPP AMP Initial Viscosity 1 Day 2 34 5 6 7 (wt (wt ASPP + Viscosity Day 3 Week 10 Weeks Weeks Weeks WeeksWeeks Weeks Sample Agg. %) %) ASPP:AMP AMP (PU) (PU) (PU) (PU) (PU) (PU)(PU) (PU) (PU) (PU) S14 1 1.5 1.5 1.0 3.0 58 >140 S15 2 1.5 1.5 1.0 3.060  71 88 104 >140 S16 1 3.00 0.24 12.5 3.24 71  80 80 82 83 83 88 89 89S17 2 3.00 0.24 12.5 3.24 70  74 76 76 78 78 81 79 82 S18 1 0.24 3.000.08 3.24 73  100 107 111 114 120 132 134 139 S19 2 0.24 3.00 0.08 3.2471  87 90 91 101 98 99 100 101 S20 1 5.00 0.24 20.8 5.24 73 >140 S21 25.00 0.24 20.8 5.24 77  88 >140 S22 1 0.24 5.00 0.05 5.24 92 >140 S23 20.24 5.00 0.05 5.24 96  106 >140 S24 1 0.24 0.24 1.0 0.48 62 74 84 90 9495 95 S25 2 0.24 0.24 1.0 0.48 54  57 63 63 62 63 64 65 67 S26 2 0.050.05 1.0 0.10 99  107 115 123 123 124 125 126 S27 1 1.00 3.00 0.33 4.063 >140 S28 2 1.00 3.00 0.33 4.0 74 >140 S29 1 3.00 1.00 3.0 4.0 70 >140S30 2 3.00 1.00 3.0 4.0 83  88 92 92 93 93 94 96 S31 2 0.05 0.05 1.00.10 68  75^((b)) 83 86 89 91 91 91 S32 3 0.05 0.05 1.0 0.10 75 93^((c)) 97 102 100 102 S33 2 3.00 3.00 1.0 6.0 90 >140^((a)) S34 33.00 3.00 1.0 6.0 100 >140^((a)) S35 2 1.53 0.79 1.94 2.31 55  62^((a))69 73 76 80 78 80 S36 3 1.53 0.79 1.94 2.31 60  77^((c)) 81 88 88 93 96S37 2 3.00 0.05 60.00 3.05 71 83 84 88 90 88 93 S38 3 3.00 0.05 60.003.05 76  88^((c)) 91 95 99 102 104 S39 2 0.05 3.00 0.02 3.05 62 77 83 8485 86 88 S40 3 0.05 3.00 0.02 3.05 72  88^((c)) 90 96 97 98 101 S41 20.05 0.05 1.00 0.10 71  75^((b)) 86 90 93 91 94 94 S42 3 0.05 0.05 1.000.10 74  95^((c)) 96 100 101 102 105 S43 2 3.00 0.05 60.00 3.05 67 81^((b)) 84 86 90 87 92 92 S44 3 3.00 0.05 60.00 3.05 78  93^((c)) 9498 99 102 103 S45 2 1.53 3.00 0.51 4.53 70 >140^((a)) S46 3 1.53 3.000.51 4.53 85 >140^((a)) PU = paste unit ASPP = alkylolammonium salt of apolyfunctional polymer AMP = alkali metal phosphate Agg. 1 = highabsorption glass aggregate (uncoated) Agg. 2 = low absorption glassaggregate (uncoated) Agg. 3 = high absorption glass aggregate (uncoated)^((a))Viscosity after 1 day testing ^((b))Viscosity after 2 days testing^((c))Viscosity after 5 days testing

The results set forth in Table 7 indicate that the lightweight finishcomposition exhibits a stable viscosity (less than 140 paste units) witha broad range of amounts of AMP and ASPP within the lightweight finishcomposition. For example, samples S16 and S17, which included 3% ASPP byweight of the lightweight finish composition, exhibited a stableviscosity after six weeks of testing. Samples 18 and 19, which included3% AMP by weight of the lightweight finish composition, also exhibited astable viscosity after six weeks of testing. In fact, Sample 18 wasstable up to 11 weeks after testing. Sample 26, which included 0.05% AMPand 0.05% ASPP by weight of the lightweight finish composition, alsoexhibited a stable viscosity after six weeks of testing.

In general, variations in the viscosity of the samples over time can beattributed to the amounts of ASPP and AMP utilized in each particularsample. With regard to the amounts of ASPP and AMP utilized, sampleswhich contained a total amount of ASPP and AMP of 4.53 weight percent orgreater had a viscosity of greater than 140 paste units before threeweeks had passed. For example, samples S20-S23, S33-S34, and S45-S46 allcontained a total amount of ASPP and AMP of 4.53 weight percent orgreater and had a viscosity of greater than 140 paste units before threeweeks had passed.

The amount of ASPP and AMP utilized and the ratio of ASPP:AMP may alsohave an effect on the stability of the lightweight finish compositionunder certain conditions. For example, among stable compositions, it wasdiscovered that if the total amount of ASPP and AMP is greater thanabout 3 weight percent of the lightweight finish composition, the ratioof ASPP to AMP or the ratio of AMP to ASPP is greater than about 3:1.Samples S14-S15 and S33-S34 had a total amount of ASPP and AMP of about3 weight percent or greater and had a ratio of ASPP to AMP and a ratioof AMP to ASPP of less than 3:1. These samples all exhibited a viscosityof greater than 140 paste units by two weeks. Samples S24-S26, S31-S32,and S41-S42 which had a total amount of ASPP and AMP of less than 3weight percent and a ratio of ASPP to AMP or AMP to ASPP of less than3:1 were stable after at least four weeks.

A lightweight finish composition is provided comprising lightweightaggregate wetted out by the combination of an alkali metal phosphate(AMP) and an alkylolammonium salt of a polyfunctional polymer (ASPP),wherein the AMP is present in an amount of from about 0.05% to about 3%and the ASPP is present in an amount of from about 0.05% to about 3% byweight of the lightweight finish composition, wherein the total amountof ASPP and AMP utilized is less than about 4.5 weight percent of thelightweight finish composition, with the proviso that if the totalamount of ASPP and AMP is greater than about 3 weight percent of thelightweight finish composition, the ratio of ASPP to AMP or the ratio ofAMP to ASPP is greater than about 3:1; and, a resin dispersion oremulsion, wherein the combination of the ASPP and the AMP providesstability to the lightweight finish composition by wetting out thelightweight aggregate such that three weeks after producing thelightweight finish composition, the viscosity as measured in paste units(PU) does not measure more than about 140 paste units.

A method of producing a lightweight finish composition is providedcomprising combining lightweight aggregate with a combination of analkali metal phosphate (AMP) and an alkylolammonium salt of apolyfunctional polymer (ASPP) to form a lightweight aggregate wetted outby the combination of the alkali metal phosphate and the alkylolammoniumsalt of a polyfunctional polymer, wherein the AMP is present in anamount of from about 0.05% to about 3% and the ASPP is present in anamount of from about 0.05% to about 3% by weight of the lightweightfinish composition, provided that the total amount of ASPP and AMPutilized is less than about 4.5 weight percent of the lightweight finishcomposition, with the proviso that if the total amount of ASPP and AMPis greater than about 3 weight percent of the lightweight finishcomposition, the ratio of ASPP to AMP or the ratio of AMP to ASPP isgreater than about 3:1; and, combining the wetted out lightweightaggregate with a resin dispersion or emulsion to produce the lightweightfinish composition.

A method of finishing a wall is provided comprising the steps ofcombining lightweight aggregate with a combination of an alkali metalphosphate and an alkylolammonium salt of a polyfunctional polymer toform a lightweight aggregate wetted out by the combination of the alkalimetal phosphate and the alkylolammonium salt of a polyfunctionalpolymer, wherein the AMP is present in an amount of from about 0.05% toabout 3% and the ASPP is present in an amount of from about 0.05% toabout 3% by weight of the lightweight finish composition, provided thatthe total amount of ASPP and AMP utilized is less than about 4.5 weightpercent of the lightweight finish composition, with the proviso that ifthe total amount of ASPP and AMP is greater than about 3 weight percentof the lightweight finish composition, the ratio of ASPP to AMP or theratio of AMP to ASPP is greater than about 3:1; combining the wetted outlightweight aggregate with a resin dispersion or emulsion to produce alightweight finish composition; and, applying the lightweight finishcomposition to the wall.

It will be understood that the embodiment(s) described herein is/aremerely exemplary, and that one skilled in the art may make variationsand modifications without departing from the spirit and scope of theinvention. All such variations and modifications are intended to beincluded within the scope of the invention as described hereinabove.Further, all embodiments disclosed are not necessarily in thealternative, as various embodiments may be combined to provide thedesired result.

1. A lightweight finish composition comprising: a) lightweight aggregatewetted out by the combination of an alkali metal phosphate (AMP) and analkylolammonium salt of a polyfunctional polymer (ASPP) wherein the AMPis present in an amount of from about 0.05% to about 3% and the ASPP ispresent in an amount of from about 0.05% to about 3% by weight of thelightweight finish composition, wherein the total amount of ASPP and AMPutilized is less than about 4.5 weight percent of the lightweight finishcomposition, with the proviso that if the total amount of ASPP and AMPis greater than about 3 weight percent of the lightweight finishcomposition, the ratio of ASPP to AMP or the ratio of AMP to ASPP isgreater than about 3:1; and, b) a resin dispersion or emulsion, whereinthe combination of the ASPP and the AMP provides stability to thelightweight finish composition by wetting out the lightweight aggregatesuch that three weeks after producing the lightweight finishcomposition, the viscosity as measured in paste units (PU) does notmeasure more than about 140 paste units.
 2. The composition of claim 1,wherein the alkali metal phosphate is potassium tripoly phosphate. 3.The composition of claim 1, wherein the alkylolammonium salt of apolyfunctional polymer is at least one of an alkylolammonium salt of apolyacrylate or an alkylolammonium salt of a polymethacrylate.
 4. Thecomposition of claim 1, wherein the lightweight aggregate is at leastone of perlite, vermiculite, fly ash, silica spheres, microballoons,extendospheres, expanded clay, pumice stone powder or combinationsthereof.
 5. The composition of claim 4, wherein the silica spheres areat least one of glass spheres or ceramic spheres.
 6. The composition ofclaim 4, wherein the lightweight aggregate is not treated with awater-repellant or a water resistant coating.
 7. The composition ofclaim 1, wherein the resin dispersion or emulsion comprises at least oneof an acrylic polymer, a non-acrylic polymer or mixtures thereof;wherein the acrylic polymer, if present, is at least one of acrylicacid, acrylic acid ester, methacrylic acid, methacrylic acid ester,styrene acrylic acid, styrene acrylic acid ester, acrylonitrile ormixtures thereof; and, the non-acrylic polymer, if present, is at leastone of polyvinyl acetate, styrene butadiene or mixtures thereof.
 8. Thecomposition of claim 1, further comprising at least one of emulsifiers,curing agents, dispersants, plasticizers, fibers, thickening agents,coalescing agents, pH modifiers, defoamers, rust inhibitors, fillers,pigments, pigment dispersing agents, solvents, or preservatives.
 9. Thecomposition of claim 1, wherein after six weeks from combining thealkali metal phosphate, alkylolammonium salt of a polyfunctionalpolymer, lightweight aggregate and resin dispersion or emulsion, theviscosity of the unset composition is less than about 130 paste units.10. The composition of claim 1, wherein the composition has a weight ofabout 45 to about 50 pounds per 5 gallons volume.
 11. A method ofproducing a lightweight finish composition comprising: a) combininglightweight aggregate with a combination of an alkali metal phosphate(AMP) and an alkylolammonium salt of a polyfunctional polymer (ASPP) toform a lightweight aggregate wetted out by the combination of the alkalimetal phosphate and the alkylolammonium salt of a polyfunctionalpolymer, wherein the AMP is present in an amount of from about 0.05% toabout 3% and the ASPP is present in an amount of from about 0.05% toabout 3% by weight of the lightweight finish composition, provided thatthe total amount of ASPP and AMP utilized is less than about 4.5 weightpercent of the lightweight finish composition, with the proviso that ifthe total amount of ASPP and AMP is greater than about 3 weight percentof the lightweight finish composition, the ratio of ASPP to AMP or theratio of AMP to ASPP is greater than about 3:1; and, b) combining thewetted out lightweight aggregate with a resin dispersion or emulsion toproduce the lightweight finish composition.
 12. The method of claim 11,wherein the alkali metal phosphate is potassium tripoly phosphate. 13.The method of claim 11, wherein the alkylolammonium salt of apolyfunctional polymer is at least one of an alkylolammonium salt of apolyacrylate or an alkylolammonium salt of a polymethacrylate.
 14. Themethod of claim 11, wherein the lightweight aggregate is at least one ofperlite, vermiculite, fly ash, silica spheres, microballoons,extendospheres, expanded clay, pumice stone powder or combinationsthereof, optionally, wherein the lightweight aggregate is not treatedwith a water-repellant or a water resistant coating.
 15. The method ofclaim 12, wherein the lightweight aggregate is uncoated silica glassspheres.
 16. The method of claim 11, wherein the resin dispersion oremulsion comprises at least one of an acrylic polymer, a non-acrylicpolymer or mixtures thereof; wherein the acrylic polymer, if present, isat least one of acrylic acid, acrylic acid ester, methacrylic acid,methacrylic acid ester, styrene acrylic acid, styrene acrylic acidester, acrylonitrile or mixtures thereof; and, the non-acrylic polymer,if present, is at least one of polyvinyl acetate, styrene butadiene ormixtures thereof.
 17. A method of finishing a wall comprising the stepsof: a) combining lightweight aggregate with a combination of an alkalimetal phosphate and an alkylolammonium salt of a polyfunctional polymerto form a lightweight aggregate wetted out by the combination of thealkali metal phosphate and the alkylolammonium salt of a polyfunctionalpolymer wherein the AMP is present in an amount of from about 0.05% toabout 3% and the ASPP is present in an amount of from about 0.05% toabout 3% by weight of the lightweight finish composition, provided thatthe total amount of ASPP and AMP utilized is less than about 4.5 weightpercent of the lightweight finish composition, with the proviso that ifthe total amount of ASPP and AMP is greater than about 3 weight percentof the lightweight finish composition, the ratio of ASPP to AMP or theratio of AMP to ASPP is greater than about 3:1; b) combining the wettedout lightweight aggregate with a resin dispersion or emulsion to producea lightweight finish composition; and, c) applying the lightweightfinish composition to the wall.
 18. The method of claim 17, wherein thealkali metal phosphate is potassium tripoly phosphate.
 19. The method ofclaim 17, wherein the alkylolammonium salt of a polyfunctional polymeris at least one of an alkylolammonium salt of a polyacrylate or analkylolammonium salt of a polymethacrylate.
 20. The method of claim 17,wherein the lightweight aggregate is at least one of perlite,vermiculite, fly ash, silica spheres, microballoons, extendospheres,expanded clay, pumice stone powder or combinations thereof, optionally,wherein the lightweight aggregate is not treated with a water-repellantor a water resistant coating.
 21. The method of claim 17, wherein thelightweight aggregate is uncoated silica glass spheres.
 22. The methodof claim 17, wherein the resin dispersion or emulsion, comprises atleast one of an acrylic polymer, a non-acrylic polymer or mixturesthereof; wherein the acrylic polymer, if present, is at least one ofacrylic acid, acrylic acid ester, methacrylic acid, methacrylic acidester, styrene acrylic acid, styrene acrylic acid ester, acrylonitrileor mixtures thereof; and, the non-acrylic polymer, if present, is atleast one of polyvinyl acetate, styrene butadiene or mixtures thereof.